Novel resinous composition



United States Patent U.S. Cl. 260-482 12 Claims ABSTRACT OF THE DISCLOSURE This invention relates to novel hydroxyl-terminated resins containing a carbamate group, at least one nitrogen atom in addition to the carbamate nitrogen and having an average minimum molecular weight of about 144. Moreover, this invention relates to novel polyurethane resins and particularly novel polyurethane foams prepared from novel hydroxyl-terminated carbamates.

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a division of US. Ser. No. 441,289, filed Mar. 19, 1965, now US. Pat. No. 3,368,985.

This invention relates to novel hydroxyl-terminated resins containing a carbamate group, at least one nitrogen atom in addition to the carbamate nitrogen and having an average minimum molecular weight of about 144. Moreover, this invention relates to novel polyurethane resins and particularly novel polyurethane foams prepared from novel hydroxyl-terminated carbamates.

More particularly this invention pertains to the preparation of novel hydroxyl-teriminated carbamates from a ureatype compound, for example, urea, thiourea, or derivatives thereof such as the carbamate reaction product of urea and a trialkanolamine, by reaction with an alkylene oxide having 2 to carbon atoms, and preferably 2 to 4 carbon atoms. Even more specifically, this invention pertains to the preparation of novel rigid polyurethane foams by the reaction of an organic polyisocyanate and the hydroxyl-terminated reaction product of a urea-type compound, preferably urea, and an alkylene oxide having 2 to 4 carbon atoms, preferably propylene oxide or butylene oxide, wherein the ratio of alkylene oxide to urea is preferably from about 2 to 1 to about 10 to 1.

The novel hydroxyl-terminated resins of this invention, which may be formed by reaction of urea-type compounds with an alkylene oxide, contain carbalmate groups and amino groups, and possess compounds of the following structure, generally in amounts of greater than about percent by weight.

wherein X is a chalcogen atom occurring in one of the short periods of the Periodic Table, that is, an oxygen or sulfur atom, each R is a 1,2-alkylene radical of 2 to 10 carbon atoms, preferably 2 to 4 carbon atoms, R and R" are hydrogen, lower alkyl, especially lower alkyl groups having 1 to 4 carbon atoms, aryl, especially phenyl, lower alkylphenyl, especially alkylphenyl groups of 7 to 11 carbon atoms, and

groups, where R may be the same or different, wherein R 3,519,680 Patented July 7, 1970 ice and R may be the same or different, and a, b or c is a number from 0 to 10, with a+b+c equal to l to 10.

Although compounds of the above structure are believed to be predominant in the novel resins of this invention, there is evidence also of the presence of carbonates of the following structure:

wherein X and R have the significance set forth above R R R and R are each an alkylene group of 2 to 10 carbon atoms, usually a lower alkylene group of 2 to 4 carbon atoms, and particularly a 1,2-lower alkylene group, wherein R R R and R are generally the same, but may be different, and d, e, f and g are numbers from 0 to 10, with the sum of d+e+f+g being a maximum of 20.

Hydroxyl-containing resins have widespread industrial widespread importance in the preparation of detergents, surfactants, polyester resins and polyurethane resins. Of the numerous hydroxyl-containing resins presently available for utilization in the preparation of polyurethane resins, one common deficiency exists, namely, that polyurethane resins prepared therefrom do not resist burning unless considerable quantities of phosphorus and/ or chlorine containing lmaterials are included in the formulation. Although phosphorus or halogen-containing additives pro duce fire retardant polyurethane resins, they frequently detract from other desirable properties of the polyurethane material.

However, it has now been discovered that novel hydroxyl-containing resins prepared from an alkylene oxide and a urea-type compound, or carbamate derivative thereof, surprisingly yield a flame retardant polyurethane resin when reacted with an organic polyisocyanate. This is particularly surprising inasmuch as other nitrogen-containing polyols, such as N,N,N ,N -tetrakis(2-hydroxypropyl) ethylene diamine do not impart flame retardant properties to polyurethane resins.

As indicated above, these novel resins are prepared by reaction of an alkylene oxide having 2 to 10 carbon atoms, preferably 2 to 4 carbon atoms, with a urea-type compound, for example, urea, thiourea, and the like, or carbamate derivatives such as those prepared by reaction of a trialkanolamine with urea, thiourea, or a substituted urea. To produce such carbamates, the preferred molar ratio of trialkanolamine to urea is less than about 2:1, with an approximately equimolar ratio being especially preferred, although at higher ratios some carbamate formation is present. Suitable trialkanolamines include triethanolamine, triisopropanolamine, tris(2-hydr0xybutylene)amine, and the like.

The invention may also be expressed as the resinous reaction product of an alkylene oxide and an organic material containing compounds of the formula:

wherein X and R have the significance set forth above, wherein y is a whole number from 0 to l, and R and R are hydrogen and R may be an alkyl or aryl group when y is 0, wherein R R and R are otherwise each selected from the class consisting of hydrogen and lower organic hydrocarbon groups having reactive hydrogens, especially lower aliphatic groups having reactive hydrogens, and particularly hydroxyalkyl groups wherein the alkyl group is a lower alkyl group, especially of 2 to 4 carbon atoms, such as hydroxypropyl groups, and where in R R and R may be the same or different. When y=1 and R is something other than hydrogen, compounds of the above formula are typically called me thanes; however, for purposes of this invention, they are referred to as carbamates inasmuch as these are considered to be N-substituted carbamates.

It is significant that these resins can be successfully utilized without removing carbonates of the above structure or free urea, which may be present in quantities up to about 20 percent by weight, although the free urea content is preferably less than about percent by weight of the resin.

It is especially significant that the inclusion of even minor quantities of the hydroxyl-terminated, nitrogencontaining resins of this invention in conventional polyurethane foam formulations contribute fire retardancy to the resulting foam, and, when major quantities of these novel materials are included in polyurethane foam formulations, the resulting foams are self-extinguishing by the standard set forth in ASTM D-1962-59T.

While the most surprising property of the novel polyurethane resins of this invention is their resistance to burning, it is also significant that they are very resistant to water vapor transmission and to oxygen transmission, and that rigid foams formed of these novel polyurethane resins have excellent resistance to heat transfer which is minimally varied by aging of the foam.

A further significant contribution of the instant invention resides in the catalytic properties which the novel hydroxyl-terminated carbamates exhibit in promoting the reaction of its reactive hydrogens with isocyanato groups. This property is especially useful in the preparation of novel polyurethane resins inasmuch as these novel carbamates effectively and rapidly promote the polymerization of the reactants in the substantial absence, and often in the complete absence, of the expansive catalysts conventionally utilized to promote the urethane reaction.

Of the urea compounds useful in the preparation of the novel urea-alkylene oxide reaction products of this invention, urea is preferred. For the purposes of this invention, however, a urea may be defined as a compound having at least three reactive hydrogens attached to urea nitrogens. Such ureas may be represented by the following formula:

wherein X is a chalcogen atom occurring in one of the short periods of the Periodic Table, that is, an oxygen or sulfur atom, preferably oxygen, R is hydrogen, lower alkyl, especially lower alkyl groups having 1 to 4 carbon atoms, hydroxyalkyl groups wherein the alkyl group contains 1 to 4 carbon atoms, aryl, especially phenyl and lower alkyl phenyl groups, and aralkyl, e.g., benzyl. Substituted ureas include:

Methyl urea Hydroxypropyl urea Ethyl urea Phenyl urea Butyl urea Benzyl urea Hydroxymethyl urea and the like.

The alkylene oxide reactants useful in this invention include alkylene oxides having 2 to 10 carbon atoms, wherein the alkylene oxide contains an oxirane group. The preferred alkylene oxides are ethylene oxide, 1,2-propy1ene oxide and 1,2-butylene oxide. When rigid polyurethane foams are prepared with halocarbon cellu- 4 lating agents, then propylene oxide and butylene oxide are preferably utilized.

The reaction of a urea of the type illustrated above and an alkylene oxide may be depicted structurally as follows, wherein propylene oxide is shown as a typical alkylene oxide:

wherein R and X have the significance set forth above. Additional moles of propylene oxide may be added to the active hydrogens attached to the nitrogen atoms.

It is generally preferred that at least about 2 moles of alkylene oxide be reacted with each mole of a urea to produce the novel resins of this invention. The maximum molar ratio of alkylene oxide to urea is about 20 to 1; however, it is generally preferred that the maximum ratio be about 10 to 1. In this regard, it is significant that when the ratio is about 4 to 1 or less, there are few, if any, ether groups present in the resin.

The novel hydroxyl-terminated reaction products of a urea-type compound or carbamate derivative thereof, and an alkylene oxide, characterized by the presence of carbamate and amino groups and some carbonate groups, can be prepared by reaction of the components under substantially anhydrous conditions or, alternatively, in an aqueous or solvent medium. When the reaction is carried out under anhydrous conditions, it is generally desirable to heat the urea component until it is in a liquid state before adding the alkylene oxide reactant. However, when propylene oxide or other high er molecular weight oxides are to be utilized, the urea may be solubilized in the liquid alkylene oxide. The reaction is generally carried out at temperatures of about 200 F. to about 300 F., although lower or higher temperatures may be utilized if desired, for example, from F. to about 500 F. The reaction is ordinarily carried out under superatmospheric pressure which is generally maintained in the range of about 50 to pounds per square inch gauge, although lower or higher pres sures may also be employed, for example, from about .10 to about 300 pounds per square inch gauge.

The reaction of a urea and an alkylene oxide may be conducted in an aqueous medium by dissolving the urea in water. The reaction is controlled by the addition of the alkylene oxide reactant. The temperature and pressure conditions are substantially as set forth above. However, the reaction may also be conducted in two stages when an aqueous medium is utilized. The reaction is allowed to proceed until the urea-alkylene oxide adduct is liquid at the reaction conditions. The water is then removed before the oxyalkylation reaction is continued. This procedure diminishes the presence of undesirable side products, such as propylene glycol and the like.

The reaction of a urea with an alkylene oxide is preferably conducted in the absence of a catalyst, however, either acidic or basic catalysts may be utilized. Suitable acidic catalysts include the mineral acids, such as sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, and the like. The basic catalysts include the hydroxides of alkaline metals and alkaline earth metals, such as lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, barium hydroxide, and the like. If it is desired to produce a product having a molar ratio of greater than 4 to 1 of alkylene oxide to urea, then it is preferred to utilize a catalyst after the first 4 moles of alkylene oxide have been added to the urea.

While the above-described methods of preparation of the novel urea-alkylene oxide reaction products of this invention are preferred, the reaction may also be conducted by dissolving the urea component in a suitable polyol, polyether polyol, hydroxyl or carboxyl-terminated polyesters, or in an inert solvent which does not react with the alkylene oxide and is capable of being removed after the reaction. Suitable polyols, polyether polyols and polyesters are set forth below.

The novel hydroxyl-terminated reaction products of this invention are characterized by a carbamate group which can be determined by a combination of infrared analysis and nuclear magnetic resonance spectroscopy, and an amino group which can be determined by conventional titration procedures, such as that described at page 105 of Quantitative Organic Analysis Via Functional Groups, by Siggia, John Wiley and Sons (second edition, 1954). The infrared analysis indicates the presence of carbonyl groups which are not urea carbonyls, while the nuclear magnetic resonance analysis indicates the presence of amide and substituted amide groups.

The novel hydroxyl-terminated resins of this invention are exceptionally useful in the preparation of rigid polyurethane foams by reaction with an organic polyisocyanate, however, they are also useful in the preparation of polyurethane coatings, polyester resins, and in detergents. The rigid polyurethane foams prepared from the novel hydroxyl-terminated polymers of this invention are especially useful for insulation applications in that they possess excellent resistance to heat transfer, good resistance to moisture permeation and good dimensional stability.

Rigid polyurethane foams prepared from conventional polyols, such as sorbitol, alpha-methyl glucoside, and the like, have densities of about 2 pounds per cubic foot and less, have water vapor permeation values in the range of about 6 perms per inch of foam thickness to about 9 perms per inch. The perm is defined in ASTM-E-96 as the water vapor transmission rate per inch of mercury dilference in vapor pressure. The units for a perm are:

Grains of water transmitted The novel rigid polyurethane foams prepared from an organic polyisocyanate and the novel hydroxyl-terminated resins of this invention have water vapor permeation values as low as about 2 perms per inch for comparable foam densities.

A further desirable property of the novel polyurethane foams prepared from the hydroxyl-terminated urea-alkylene oxide adducts of this invention resides in their excellent compatibility with the halocarbons widely utilized as blowing agents in polyurethane foams. This is especially true when propylene oxide or butylene oxide is used to prepare the novel urea-alkylene oxide adducts.-This excellent compatibility with halocarbons is important in that it permits the preparation of rigid polyurethane foams having densities as low as about 1.2 pounds per cubic foot Which retain, to a great degree, the outstanding physical properties of the more dense foams. This is advantageous inasmuch as rigid polyurethane foams derived from conventional polyether polyols cannot be prepared with densities of less than about 2 pounds per cubic foot Without deleteriously affecting the physical properties of the foam.

Novel polyurethane resins may be prepared from the novel hydroxyl-terminated urea-alkylene oxide products described above by the reaction of approximately one equivalent of the hydroxyl-terminated resin with one equivalent of an organic polyisocyanate. While the hydroxyl-terminated urea-alkylene oxide reaction products tend to promote the urethane reaction, on occasion it may be desirable to include a small amount of a suitable urethane catalyst. Also ordinarily included in the foam formulations are suitable emulsifiers.

Organic polyisocyanates which are reactive with the novel urea-alkylene oxide reaction products of this invention to form novel polyurethane resins include the following:

Toluene diisocyanate Chlorophenyl-Z,4-diisocyanate Ethylene diisocyanate 1,4-tetramethylene diisocyanate Para-phenylene diisocyanate Hexamethylene diisocyanate and the like. While the above diisocyanates may be reacted with the novel alkylene oxide-urea reaction products to form coatings or foams, it is preferred to form prepolymers of said diisocyanates when they are to be used in rigid foam formulations.

When it is desired to form polyurethane foams directly from an organic polyisocyanate and the novel resins of this invention without first preparing a prepolymer, it is preferred that poly-nuclear polyisocyanates of the following type be included:

Diphenyl diisocyanate Triphenyl diisocyanate 3,3'-dimethyl-4,4-biphenylene diisocyanate 3,3-dimethoxy-4,4-biphenylene diisocyanate Polymethylene polyphenyl isocyanate diphenylmethane- 4,4-diisocyanate Triphenylmethane triisocyanate 1,5-naphthalene diisocyanate 3,3'-dimethyldiphenylmethane-4,4'-diisocyanate and the like. Of the preferred polyisocyanates, it has been found that the best results have been obtained when the polymeric polyisocyanates having a functionality greater than 2.0 are utilized. Exemplary polymeric polyisocyanates include the following:

Crude diphenylmethane-4,4-diisocyanate, commonly referred to as crude MDI, having a functionality of about 2.5 to 2.6. Furthermore, although solid organic polyisocyanates can be utilized in the instant invention by melting them prior to reaction with the other foam-forming ingredients, it is preferred that liquid organic polyisocyanates be utilized.

Another organic polyisocyanate particularly useful is crude toluene diisocyanate, commonly referred to as crude TDI, containing about percent TDI and about 15 percent polymeric isocyanate and having a functionality of about 2.1.

Polymethylenepolyphenyl isocyanate, referred to as PAPI, having an isocyanate functionality greater than about 2.4, has been found to be particularly useful.

The relative amount of organic polyisocyanate utilized in polyurethane foam formulations is susceptible of variation over a substantial range. Usually, the isocyanate component is employed in an amount which provides approximately one reactive isocyanato group for each reactive hydrogen of the other component, which is conventionally a polyol, polyamine or similar reactive hydrogen-containing material. However, some of the organic polyisocyanates tend to evaporate and it may be desirable to compensate for this loss. A range of about /2 equivalent to about 2 equivalents of organic polyiso cyanate per equivalent of polyol component in the final material is ordinarily used, but smaller or larger amounts can be utilized with good results.

While useful polyurethane resins are formed by the reaction of an organic polyisocyanate and the novel ureaalkylene oxide reaction products of this invention, it has been found that other reactive hydrogen-containing components such as various long chain aliphatic polyols, polyether polyols, polyester polyols, and the like, may be included without substantially detracting from the excellent properties of the polyurethane resins of this invention. In some cases, it has been found that inclusion of another reactive hydrogen-containing component has resulted in improvements in certain of the properties :of polyurethane foams formed from an organic polyisocyanate and the novel hydroxyl-containing resins of this invention, for example, improved surface characteristics have been obtained.

Aliphatic polyols useful in this invention include those diols which are separated by a carbon chain of 6 to 20 or more carbon atoms. Since such diols are only difunctional, they are ordinarily included only as minor amounts as a reactant in foam formulations designed to produce the novel rigid foams of this invention. For purposes of this invention, minor amounts of aliphatic diols may be defined as amounts which do not detract from the rigidity of the cured foam nor detract from the excellent dimensional stability of the foam.

Aliphatic triols such as hexanetriol and polyether polyols prepared by the oxyalkylation of said aliphatic triols, may be used in minor or major quantities in the foam formulation of this invention. It is preferred, however, that additional reactive hydrogen components be more than trifunctional and that the trifunctional polyols and polyether polyols be used in relatively minor quantities. The aliphatic triols which may be included as additional reactive hydrogen component include aliphatic triols having 6 or more carbon atoms. Typical triols include the following:

Trimethylolethane Glycerol Trimethylolpropane 1,2,6-hexanetriol and the like. The trifunctional polyether polyols useful in the preparation of rigid polyurethane foams have a hydroxyl number in excess of about 200 and preferably should have a hydroxyl number in excess of about 300.

Tetrafunctional polyether polyols and polyether polyols of higher functionality are prepared by the reaction of an alkylene oxide, such as ethylene oxide, propylene oxide or butylene oxide, with a polyol having 4 or more available hydroxyl groups. Typical tetrafunctional and higher functional polyether polyols are prepared by the oxyalkylation of polyols such as the following:

Pentaerythritol Sucrose 2,2,6,6-tetrakis (hydroxymethyl)cyclohexanol Glucose Sorbitan Mannitan Degraded starches Degraded cellulose Diglycerol Alpha-methyl glucoside and the like. When such polyether polyols are utilized in the novel rigid polyurethane foams of this invention, they should have a hydroxyl number in excess of about 200 and preferably in excess of about 250, with the best results ordinarily being achieved from those polyether polyols having hydroxyl numbers in excess of about 300.

In addition to the aliphatic polyols and the polyether polyols, polyester resins containing hydroxyl groups may be utilized in conjunction with the novel hydroxyl-terminated urea-alkylene oxide reaction products to prepare useful rigid polyurethane foams. Suitable polyester resins may be prepared by reacting an excess of polyol with a polycarboxylic acid, especially dicarboxylic acids. Typical polyols include:

Ethylene glycol Trimethylolethane Propylene glycol 1,2,6hexanetriol Butylene glycol Pentaerythritol Glycerol Diethylene glycol Trimethylolpropane Dipropylene glycol and the like. Typical dicarboxylic acids include: Adipic acid Phthalic acid Succinic acid Isophthalic acid Azaleic acid Terephthalic acid and the like, and the corresponding anhydrides where such anhydrides exist. Also, long chain dimer acids may be used to form useful polyols by esterification with polyols,

especially diols such as ethylene glycol and the like. For

the purposes of this invention, useful polyesters should have a minimum hydroxy number of about 200, and preferably above about 250, with bset results being obtained from those polyesters having hydroxyl numbers in excess of about 300.

Other active hydrogen-containing materials which may be present in the novel urethane foams of this invention include phenol-formaldehyde condensation products, aminic compounds such as diethanolamine, triethanolamine, diethylenetriamine, 1,6-hexamethylene diamine, and the like, as Well. as oxyalkylation products of these active hydrogen-containing materials and aliphatic polyamines, such as N,N,N,N tetrakis(2 hydroxypropyl)- ethylene diarnine. Another material which may be present in the foams of this invention is castor oil and its derivatives. Also useful are the oxyalkylation products of polyamine polyamide compounds as obtained by the reaction of dicarboxylic acids With polyamines.

For a more complete understanding of available raw materials for the manufacture of polyurethane resins, especially polyurethane foams, and methods of preparing these raw materials, reference may be had to Polyurethanes: Chemistry and Technology, vol. I, by Saunders and Frisch, Interscience Publishing Company (1962), especially pages 17 through 54, inclusive.

In addition to the reactive hydrogen-containing components listed above, it has been found that the inclusion of water in rigid foam formulations based upon the novel urea-alkylene oxide reaction products disclosed-herein, may give certain beneficial effects. Water, of course, will promote cellulation by reaction with dicyanato groups to produce carbon dioxide, however, in addition to causing cellulation, it has been found to improve to some extent the dimensional stability of certain rigid polyurethane foams produced according to the teaching of this invention.

To promote the polyurethane linkage reactions in the final curing of the polyurethane resins, catalysts are usually required. These include tertiary amines of hydroxyl amines, organic salts of tin, and the like. The following constitutes a partial list of such catalysts:

Tetramethylethylenediamine (anhydrous) (TMEDA) Tetramethyl guanidine (TMG) Tetramethyl-1,3 butanediarnine (TMBDA) Triethylenediamine of the formula:

Dimethylethanolamine (DMEA) Tin esters, such as:

Stannous oleate Stannous octoate Dibutyl tin 'dilaurate and the like.

Many other catalysts may be substituted for those listed above, if desired. The amount of catalyst used may bein a range of about 0.05 percent to about Spercent or more by weight based upon the total of thepolyols employed. Mixtures of the above and/or other catalysts may also be utilized.

=To impart a foamed or cellular structure to the blended polyol-polyisocyanate mixture, a suitable gassing agent or system of gassing agents must be added or produced in situ. The liquid but relatively volatile halocarbons, such as the following perhalocarbons containingl, 2 or even up to 4 carbon atoms, are especially desirable for the purpose. These include the following:

CCl F CHCl F cclzFg C 5 2 2 8. CHCIFZ The halocarbons having 1 and 2 carbon atoms are preferred, and of these, trichloromonofluoromethane and dichlorodifiuoromethane are particularly useful in commercial preparations. These are added as liquids in quantities of about percent or less to about percent or more, by weight of the total resin to the blended polyol-polyisocyanate mixtures, or to one or more components thereof, and are substantially volatilized in the liquid mixture to effect cellulation. Subsequently, the mixture cures to a hardened, cellular state.

Although the halocarbons are especially desirable as blowing agents when exceptional insulative properties are desired, other blowingagents, such as water, carbon dioxide, and the like, can be utilized in this invention.

In order to obtain relatively uniform distribution of the various components of the liquid system and to achieveproper cellulation, an emulsifier and/or surfactant may be incorporated into the mixture. These materials are physical in their effect and are not always necessary, especially if denser foams are desired. Many hundreds of these are available as commercial products. Some of these are listed in the publication Detergents and Emulsifiers- Up to Date 1960, published by John W. McCutcheon, Inc., 475 Fifth Ave., New York 17, N.Y.

Examples of surfactants which maybe used include the so-called Pluronics, which have been described as being condensates of ethylene oxide with a hydrophobic base formed by condensing propylene oxide with propylene glycol. These are of a molecular weight in a range of about 2000 to about 8000 and are ascribed the structure:

Another class of surfactants comprises the so-called Tetronics, which are formed by the addition of propylene oxide to ethylene diamine, followed by the addition of ethylene oxide. These compounds have been ascribed the structure:

product is of the approximate structure:

in which R and R"" are monovalent hydrocarbon radicals, while R is a divalent hydrocarbon radical; p, q, and r are integers equal to at least 1 and may be considerably higher, e.g., 2, 3, 4, 5, 6, or a higher number up to about 20; n is a whole number from about 2 to about 4; and z is an integer equal to at least 5 and may be higher, e.g.,

6, 7, 8, 9, 10, or even higher, up to about 25. One such material is sold as Dow Corning-199. Still another highly 75 Other surfactants, especially the liquid or soluble nonionic ones, are also useful. The sufractants may be employed in amounts within a range of about 0.1 to about 3 percent by weight based upon the mixture of polyol component and the organic polyisocyanate component. In relatively dense foams, for example, those weighing about 5 or 6 pounds and upward per cubic foot, the surfactants may be omitted entirely.

The following examples illustrate in detail the preparation of the novel polyhydroxy resins and polyurethane foams thereof of this invention, but the invention is not to be construed as being limited solely thereto.

EXAMPLE I Urea-propylene oxide reaction About 8.0 gram moles (480.1 grams) of urea and 32.0 gram moles (1856 grams) of propylene oxide were reacted in the presence of 2.4 grams of potassium hydroxide.

The urea and potassium hydroxide were charged to an autoclave having external heating means. About 600 grams of propylene oxide were added and the temperature was gradually raised to about 240 F. Because of the exothermic reaction from this 600-gram portion of the propylene oxide, the maximum pressure attained was 230 pounds per square inch gauge and the maximum temperature reached was 310 F. When the pressure of the reaction vessel had dropped to 70 pounds per square inch guage, the remaining amount of oxide was added intermittently over about a 5-hour period. During the addition of the remaining portion of the propylene oxide, the autoclave pressure was maintained at about 70 pounds per square inch guage and the temperature was maintained at about 260 F.

After all of the propylene oxide reactant had been added, the temperature of the autoclave was maintained at about 260 F. for about 1 hour. At this point, the autoclave pressure had diminished to about 28 pounds per square inch gauge, indicating that the reaction was nearing completion. After allowing the reaction to go to completion, the contents of the reaction vessel were removed.

The reaction product had a hydroxyl number of 626.6.

EXAMPLE II Reaction of 1 mole of urea with 4 moles of propylene oxide and foams thereof A urea-propylene oxide polyol was prepared from the following materials:

Moles Grams Urea 8. 0 480 Propylene oxide 32.0 1, 856

were charged to an autoclave having external heating ditions. The results of those distortion tests are shown means. The reaction vessel temperature was gradually in the following table:

EXAMPLE II, TABLE 2 Test Conditions Foam IIC Foam IID 200 F. for 48 hours and 1 percent expansion, very slight distortion 0 an%1 percent expansion, very slight distortion.

200 F. for 1 week o o. 200 F. for 2 weeks 0 and 0.8 percent expai n, very slight distortion- 0 and 0.8 percent expansion, very slight distortion.

158 F., 100 percent relative humi l y for 0 and 0.8 percent expansion, no distortion 0 percent expansion, no distortion.

24 hours. 158 F., 100 percent relative humidity 0 and 2 percent expansion, very slight distortion.. 0 and 2 percent expansion, very slight distortion.

for 1 Week. 158 F., 100 percent relative humidity 1.2 and 1.2 percent expansion, very slight distortion. 0.8 and 1.6 percent expansion, very slight distortion.

for 2 weeks. 158 F., 100 percent relative humidity 1.5 and 2 percent expansion, very slight distortion. 1.5 and 1.5 percent expansion, very slight distortion.

for 4 weeks.

raised over a 30-minute period to about 250 F. At this Foams IIC and IID were observed to have improved temperature, the pressure was about 140 pounds per square p p r es fter 6 days of room temperature curing After inch gauge and the reaction was observed to be in the this addlilonal cllflng Epefilod, thefoams had 811.111 1 initial stages of an exothermic reaction. The pressure of faces Whlch were y sllghtly fflable and the lll'lerlor the reaction vessel reached about 215 pounds per square 3 f t g flai it l r 1 d inch gauge and the maximum temperature attained was p yg z ag i g t zngon viit l l iigvggz'igsgl 1 :31;

ontents were maintained at abtotu F g liggi g to about F and the 01s, foams were prepared from a blend of the crude a emper urea-propylene oxide polyol prepared above (Example pressure was gradually reduced to about 70 pounds per 11) and a Sucrose polyether polyol Prepared by Square fl and was mfm'ltamed there by i Inter" acting 1 mole of sucrose with 12.3 moles of propylene m1ttent addition of the remaining propylene oxide over Oxide and 4 moles f ethylene oxide and having a a period of about 3 hours. When the autoclave pressure hydroxyl number f 0 The results f this experiment had reduced to 0 pounds per square inch gauge, the are t b l t d i T bl 3, reaction product was recovered. EXAMPLE 11, TABLE 3 The crude reaction product had a viscosity of 1130 Material Foam HF Foam HG centipoises, a hydroxyl number of 639.2, and a nitrogen Nacconate 4040 100 grams 100 grams. content Of 9.33 percent. Sucrose polyol 107.0 grams. 95.0 grams. Part of the crude product was distilled under vacuum gi k j l ggw X1de gmms grams' at a temperature of 120 C. (maximum) and in the pressin ifiuisincr 1.0 ra i n 1.0 grgft .8 1 0.1 DA 1.9 mi i' ers. 1.9 m 'iers. encepf apout prcent by Weight 85 percent.plflos Triehloromonofluoromethane. 42.5 grams. 41.5 grams. phoric acid. The purified product contained 1n the distilla- Mlxlnr at 85 -p- 12 s 11 Seconds- Cream time 17 seconds 14-15 seconds. tion vessel was recovered and filtered. The purified leac- Set time 32 seconds 70 seconds.

Remarks Foam had good Foam had good tron product had a hydroxyl value of 646.4, a Brookfield appearance and appearance and viscosity at 77 F. of 1298 centipoises, a Water content 40 gas nofii r isgle. hlztdhlznly {very earn a e S 1 SUI 8.06 of 0.11 percent by weight, and an ac1d value of 020. cells and was Foam Foams were prepared of the crude reaction product fairly strong. had fine and was fairly and of the purified reactlon product with Nacconate 4040 strong. although and PAPI. The foam formulations and properties are conff s rong as tamed in Table 1.

EXAMPLE II, TABLE 1 Material Foam HA Foam 11B Foam 1T0 Foam IID Foam IIE Nacconate 4040 l 100.0 grams.--" 100.0 grams PAPI 100.0 gram 105.0 grams. Purified urea-propylene oxide polyol (0 -64 65 0 grams. 47.0 grams. Crude urea-propylene oxlde polyol C 011-639) Phosphorus polyol 3 45.0 grams. Silicone emulsifier. .0 gram 1.0 gram 1.0 gram 1.0 gram 1 0 gram 1.0 DMEAIOA DABCO (trlethylenedlamine). 1.5 milli1iters 1.5 milliliters- Tetramethylbutanediamine 0.4 millilit 0.4 milli 0.6 milliliter. Trichlorgmonofluoromethane 30.0 grams. 25.0 grams 25.0 grams 31.0 grams. MlXlIlg time at 850 rpm... 7 seconds- 7 seconds 10 seconds 10 seconds 10 seconds. Cream time 9 secon 27 seconds 27 con 38 seconds. Set time 34 seconds 76 seconds.-- 74 seconds"--. 110 seconds.

Very good. Fine Fine..." Fine.

Friable SklIl..- Friable sk1n Friable inable inside non-friable non-friable side and H and skin. inside. Compatibility of premix and isocyanates Good G Interior foam strength, 2 hours cure at room temperature- Very weak- Primary shrinkage after 1 hour room temperature cure None N Slight.

1 Nacconate 4040, A crude isocyanate composition having a functionality of 2.1 and containing approximately equal parts of 2,4-isomer and 2,6-isomer of TDI and about 15 percent by weight of polymeric isocyanate materials.

2 PAPI Polymethylene polyphenyl isocyanate, functionality of above about 2.4.

3 Monoisobutyl phosphates and diisobutyl phosphates reacted with propylene oxide to a hydroxyl number of about 260.

4 Cream time 15 the term used to designate the length of time required for a resin to begin cellulation, as determined from initial mixing.

Foams IIC and IID were the best foams of the foams prepared in Table 1 of Example I I. Foam IIC had a density of 1.83 pounds per cubic foot and a water vapor Foams HF and IIG had densities, respectively, of 1.55

transmission value of 2.40 perms per inch. Foam IID pounds per cubic foot and 1.50 pounds per cubic foot. had a density of 1.86 pounds per cubic foot and a water These foams were subjected to high temperatures and vapor transmission value of 2.32 perms per inch. The high humidity conditions to test the expansion and disresistance to expansion and distortion of these foams tortion resistance. These results are tabulated in'Table was tested at high temeprature and high humidity con- 75 4below.

EXAMPLE II, TABLE 4 Test Conditions Foam IIF Foam 11G 200 F. for 48 hours 1 and 2 percent expansion, slight distortion-... 2 and 2 percent expansion, slight distortion.

200 F. for 1 week 2 and 4 percent expansion, slight distortion- 2 and 4 percent expansion, slight distortion. 153 F.', 100 percent relative humidity for 24 hours..... and 2 percent expansion slight distortion.

0 and 2 percent expansion, slight distortion.

158 F., 100 percent relative humidity for 1 week 2 and 4 percent expansion, slight distortion 1.5 and 2 percent expansion, slight distortion 158 F., 100 percent relative humidity for 2 weeks 6 and 6 percent expansion, slight distortion. 4 and percent expansion, slight distortion It was observed that the foams prepared from a blend about 250 F., the pressure was allowed to reduce to of a urea-propylene oxide polyol and a sucrose polyabout 70 pounds per square inch gauge. The pressure was ether polyol had better surface characteristics than the then maintained at about 70 pounds per square inch gauge foams prepared solely from urea-propylene oxide polyols. by the incremental addition of propylene oxide. The pro- In those applications in which surface friability would pylene oxide addition required about 5 hours. The pressure be undesirable, the foams HF and IIG would be preof the autoclave was allowed to reduce while maintaining ferred. However, the inclusion of a sucrose polyether the temperature at about 260 F. Of the 2442 grams polyol appeared to detract from the expansion and discharged, about 2270 grams of reaction product were retortion resistance of the foams when subjected to high covered.

temperature and high humidity conditions. Thus, for The crude reaction product was purified by stripping it applications where the foams would be subjected to high of volatile materials by distillation under vacuum in the temperatures and high humidity conditions, the foams presence of about 2.2 grams of 85 percent phosphoric prepared from a urea-propylene oxide polyol would be acid. The reaction product was heated to about 90 C., preferred. at Which time vacuum was applied. The reaction product EXAMPLE III was distilled at a temperature of about 120 C. while maintaining a vacuum of about 15 millimeters of mercury. The reaction product was vacuum distilled for about A hydfoxyl'termlnated carbamate polyol was Prepared 1 hour. Of the 2249 grams of material charged, about the following ingredients: 2218 grams of purified reaction product were recovered. The purified reaction product had a hydroxyl value of Reaction of 1 mole of urea with 6 moles of propylene oxide Moles Grams 574.4 and a moisture content of 0.11 percent by weight U 6.0 360 rr tifl lene oxiden 36.0 2,080 water Several rigid foams were obtained by reacting the pun- T he urea, 450 grams of propylene oxide and 2.12 grams l reaction Product Wit]? Various ypf 0f QYgaIlic 1 9 3- of percent t iu hydroxide were h d t an isocyanates. The proportions of the ingredients utilized autoclave having external heating means. The reaction and the properties of the resulting foams are tabulated mixture was agitated and the temperature was raised gradbelow:

EXAMPLE III, TABLE 1 Materials Foam 111A Foam IIIB Foam IIIC Nacconate 4040. 100.0 grams Mondur-MR 1 PAPI 1000 grams.

Purified urea-propylene oxide polyol (OH-574.4) 0 grams 77.9 grams.

Silicone emulsifier 1.0 gram. 1 0 1.0 gram.

1.8 DMEA/O 1 DABCO- 1 0 milliliter Trichlorofluoromethane. 32.0 grams--. 29.0 grams.

Mixing time at 850 r.p.m 10 seconds-... 10 seconds.

Cream time 16-17 seconds. 45 seconds.

Set t'me 70-80 seconds 67 seconds seconds.

Properties of foam after curing at room temperature for 15 hours Extremely friable Very friable and Friable and weak and weak cell weak cell cell structure, structure. structure. but better than Foams IIIA and THE.

Foam appearance Good foam appear- Good foam appear- Good foam appearance with fine cell ance with fine cell ance with fine structure. structure. cell structure.

Density, pounds per cubic foot 1.68 1.66.

l Mondur-MR designated p,p-diphenylmethane diisocyanate having a functionality of about 2.5 to 2.6.

ually to about 300 F., at which time the maximum pres- Additional rigid foams were prepared from the urea sure of pounds per square inch gauge was achieved. propylene oxide polyol and the polymethylene polyphenyl The maximum temperature reached was 305 F. While isocyanate (PAPI) since the best results were obtained maintaining the temperature of the reaction mixture at 75 with that isocyanate. The proportions of the foam ingredi- 1 5 cuts and the properties of the resulting foams are tabulated below:

sure reached 0 pound per square inch gauge. This required a period of about 4 hours. About 2793 grams of crude EXAMPLE III, TABLE 2 Materials Foam IIID Foam IIIE Foam IIIF Foam IIIG Foam IIIH PAPI 105.0 grams 105.0 grams 105.0 grams 100.0 grams 100.0 grams. Purified urea-p0 QPurified urea-propylene 67.0 grams. 63.0 grams 58.0 grams 77.0 grams. 77.0 grams.

oxide polyol (OH-574.4). Phosphorus polyol (OH-260), prepared by 20.0 grams 30.0 grams- 40.0 grams.

reaction of propylene oxide with a mixture of monoand dibutyl acid phosphate. Silicone emulsifier 1.0 gram 1.0 am 1.0 gram 1.0 gram. TMBDA 1.5 milliliters 1.5 milliliters. 0.8 milliliter 1.5 milliliters. Trichloromonoiiuoromethane 30.0 grams 31.0 grams 29.0 grams 29.0 grams. Mixing time at 850 r.p.m seconds 15 seconds 20 seconds" 20 seconds. Cream time 28 seconds 27 seconds. 28 seconds. 35 seconds. seconds. Set time 87 seconds 85 seconds 88 seconds- 105 seconds. 85 seconds. Density, pounds per cubic foot 1.87 1.91 1 651 1.72. Properties of foam after 1 hour cure at room Friable and weak. Friable and Weak. Frlalole and weak. Friable and temperature. Some primary Some primary Some primary No primary weak. No prishrinkage. shrinkage. shrinkage. skrinkage. mary shrinkage. Properties of foam after 16 hours cure at Friable and weak. Friable and weak. Friable and Weak. Friable and weak. Friable and room temperature. Good foam ap- Good foam ap- Fine cell strue- Good f0am ap weak. Good pearance with pearanee with ture and slight pearance with foam appearfine cell structure. fine cell structure. primary shrikfine cell structure. ance and fine Very slight pri- Very slight age. cell structure. mary shrinkage. shrinkage.

No'rn.-The above foams were prepared by initially admixing all the ingredients other than the isocyanate, and then admixing this blend with the organic polyisocyanate.

EXAMPLE IV Reaction of 1 mole of urea with 7.55 moles of propylene oxide A hydroxyl-terminated carbamate polyol was prepared from the following ingredients:

Moles Grams Urea 6. 0 360 Propylene oxide 45. 3 2, 630

25 reaction product were recovered from the 2992 grams of material charged.

The crude reaction product was purified by vacuum distillation, thereby removing the volatile impurities. About 2784 grams of the crude product were distilled in the presence of about 2 grams of 85 percent phosphoric acid at a temperature ranging from about 90 C. to about 120 C. and a vacuum of about 15 millimeters of mercury. The distillation required about 90 minutes. About 2740 grams of reaction product were recovered. The purified reaction product had a hydroxyl number of 468, a viscosity of 524 centipoises, moisture content of 0.213 percent by weight of water, and an ash content of 75 parts per million.

Rigid foams were prepared by reacting the purified urea-propylene oxide polymer with various isocyanates in the manner set forth in the following table:

EXAMPLE IV, TABLE 1 polyol (OH-468) Silicone the exothermic reaction taking place. The maximum pressure of 150 pounds per square inch gauge was reached when the temperature had increased to 300 F. The temperature was maintained at about 260 F. to 265 F., while the reaction pressure dropped to about 70 pounds per square inch gauge. The pressure of the reactor was then maintained at about 70 pounds per square inch gauge by the incremental addition of the remaining propylene oxide. Propylene oxide was added incrementally for about 6 hours. At this point, the reaction was discontinued for a period of 16 hours. At the end of the 16- hour period, the reaction mixture was again heated to about 260 F. The pressure remained at 0 pound per square inch gauge, indicating the absence of substantial quantities of unreacted propylene oxide. The propylene oxide addition was resumed and the pressure was raised to 75 pounds per square inch gauge. The propylene oxide addition was continued for about 10 minutes. Upon completion of the propylene oxide addition, the reaction pressure began to drop. The reaction temperature, however, was maintained at about 260 F. until the reaction pres- 1.0 milliliter 0.4 milliliter... 0.7 milliliter.

35 grams 31 grams 31 grams. 15 seconds. 15 seconds 15 seconds. 25 seconds. 25 seconds 30 seconds.

-11100- seconds 65-70 seconds -120 seconds.

Foam IVA was initially very friable and weak. The interior of the foam was still weak and friable after curing at room temperature for 24 hours.

Foam IVB was initially friable and weak inside. The foam, however, had good appearance and fine cell structure, although it was still slightly friable and Weak internally after curing at room temperature for 24 hours. The foam had a density of 1.81 pounds per cubic foot.

Foam IVC was initially friable and weak inside, although having good appearance and fine cell structure. The foam was still slightly friable and weak internally after curing at room temperature for 24 hours. This foam' had a slight amount of primary shrinkage.

EXAMPLE V Reaction of 1 mole of urea with 4 moles of propylene oxide in the presence of water and H 50 In Examples I through IV, inclusive, hydroxyl-terminated carbamate polyols were prepared from urea and propylene oxide in the substantial absence of water and in the presence of a basic catalyst. The present example Moles Grams Water 90 Urea 8. 510 Concentrated sulfuric acid 10. 2

After the above solution of ingredients had been added to the preheated reaction vessel, the temperature of the reaction mixture was raised to about 220 F. Propylene oxide was added incrementally to maintain the reaction pressure at about 55 pounds per square inch gauge. A total of about 2090 grams of propylene oxide (about 36 moles) were added over a 9-hour period. After all the propylene oxide had been added, the reaction vessel temperature was maintained at about 260 F., thereby permitting the remaining amount of unreacted propylene oxide in the vessel to reactand the reaction pressure thereby decreasing. About 2438 grams of crude reaction product were obtained.

The crude reaction product was purified by stripping it of the more volatile materials. About 2412 grams of the crude product were heated to a temperature of about 80 C. in a vacuum distillation apparatus. At this temperature vacuum was applied and the product was distilled under a vacuum of about millimeters of mercury at a temperature range of about 80 C. to about 120 C. for a period of about 2 /2 hours. The distillation residue was filtered and about 2336 grams of purified reaction product were recovered. The purified reaction product had a Foam VB was initially slightly friable, although it had fine cell structure and good appearance. After curing at room temperature for 24 hours, the foam became tough internally, although still slightly friable on the surface. The foam exhibited some primary shrinkage.

Foam VB is of special interest in that it exhibits the auto-catalytic properties of the carbamate polyols of the instant invention. No reaction catalyst was included in the foam formulation of foam VB.

The heat distortion resistance of foam VB was tested. The results are tabulated below:

EXAMPLE V, TABLE 2 Percent Distortion Length Width Thickness Test Conditions 2 inches 2 inches 1 inch 200-F. for 24 hours 0. 78 O -2. 3

200 F. for 72 hours. 0.39 0 1. 5

200 F. for 1 week 0. 78 0. 78 1. 5 158 F., 100 percent relative humidity for 24 hours 0.78 0 1. 56 158 F., 100 percent relative humidity for 1week 0. 78 0.39 l. 5 158 F., 100 percent relative humidity for 2.weeks 0.78 0. 78 l. 5 158 F., 100 percent relative humidity for 4 weeks 2. 2 1. 95 -1. 5

-The following table illustrates the effects of certain phosphorus-containing compounds upon the properties of polyurethane foams prepared from the urea-alkylene oxide adducts of this example.

The polyurethane foams illustrated below were prepared in a typical manner, that is, all the ingredients other than the polyisocyanate were admixed with the urea-propylene oxide polyol and then this mixture was blended with the organic polyisocyanate to form a rehydroxyl value of 677.8, a viscosity of 680 centipoises at active, foam-forming mixture.

EXAMPLE V, TABLE 3 Foam VG Ingredients Foam VO Foam VD Foam VE Foam VF PAPI 110.0 gram 1100 rams 110.0 grams 110.0 rams 110.0 grams, Urea-propylene oxide 55.0 grams. 55.0 grams-.--- 55.0 grams- 55.0 grams-..- 55.0 grams.

plolyol (OH-677) Phosphorus polyol (0 260) 'lris(diehloropropyl)-pl1osphate. Tctramethylbutanediamine...

Liquid non-ionic surfactant (molecular weight, 2,120, hydroxyl number,

Tricliloromonofluorornethane Mixing time at 850 r p m 25.0 grams.. 15 seconds. 15 seconds..-..

.. 20.0 grams...-- 20.0 grams...-. 20.0 grams 20.0 grams..- 20.0 grams.

15,0 m'amc g 0.4 milliliter... 0.4 milliliter-.. 0.4 milliliter... 0.4 milliliter. Silicone emulsifier 1.0 gram.

15.0 grams 15.0 rams 15.0 grams-. 25.0 rams.

1.0 gram 1.0 gram.

Cream time... seconds 30 seconds 33 seconds 34 seconds..-- 39 seconds. Set time 113 se 82 seconds 85 seconds 87 seconds 98 seconds. Density of cured foam, pounds per cubic foot .16 2.16 2.36. Water vapor transmission of cured foam, perms per inch 2.57 3.38 3.94.

EXAMPLE V, TABLE 1 Materials Foam VA Foam VB Nacconate 4040 100 grams PAPI 100 grams. Urea-propylene oxidepolyol 76. 5 grams. 62 grams.

(hydroxyl number, 677.8).

Silicone emulsifier gr 1.0 gram. 1.8 DMEA/OJ DABCO. 0 6 milliliter Trichloromonoiluoromet 29 grams 26.5 grams. Mixing time at 850 r.p.m 6 seconds 10 seconds. Cream time ...do. 33 seconds. Set time 15-30 seconds-... 83 seconds. Density, pounds per cubic foot 1.36 1.67. Water vapor transmission, perms per inch 2.42.

Foam VA was initially friable, however, it had fine cell structure and good appearance. After curing at room temperature for 24 hours, the foam had a tougher interior but was still friable on the surface.

Foam VC evidenced a slight amount of initial friability, had a fairly tough interior and good over-all foam appearance. This foam was self-extinguishing and when tested in accordance with the procedures of ASTM-D- 1692-59T, it burned to 1 inch in 40 seconds and self extinguished in 43 seconds.

Foam VD was poor in appearance, had medium cell structure and evidenced signs of incompatibility.

Foam VE had fair appearance and fine to medium cell structure. This foam also evidenced signs of incompatibility.

Foam VF had good foam appearance, a slight amount of initial friability and a tough interior. This foam evidenced some surface adhesion to the mold and fair primary shrinkage. The foam became tougher after curing at room temperature for 24 hours. This foam was also self-extinguishing and when tested in accordance with ASTM-D-1692-59T test procedures, it burned to 1 inch in 34 seconds and self-extinguished in 40 seconds.

Foam VG had good appearance, slight initial friability and a tough interior. This foam evidenced slight adherence to the mold and fair primary shrinkage. This foam became tougher after curing at room temperature for 24 hours. This foam was self-extinguishing in 37 seconds and burned only 0.95 inch in that time. The flame re- 19 tardancy was tested in accordance with ASTM-Dl692- 59T procedures.

EXAMPLE V, PART II The urea-alkylene oxide reaction product of this example was further distilled to remove the low molecular weight fractions. This distillation was conducted in a distillation vessel equipped with temperature recording means, an azeotrope separator, condenser, and external heating means.

About 400 grams of the urea-alkylene oxide resin having a hydroxyl number of 677 were charged to the distillation vessel and gradually heated to about 116 C., at which time the pressure in the distillation vessel was reduced to about 150 millimeters. The distillation proceded for about 1 hour and the temperature gradually raised to 130 C. while the vacuum was lowered to about 1.8 millimeters of mercury.

About 356 grams of product were recovered and about 40 grams of distillate were recovered. The distillate had a slight odor of ammonia, a nitrogen content of about 0.66 percent, and a hydroxyl value of 1313. The refined alkylene oxide-urea resin had a nitrogen content of 9.44 percent and a hydroxyl value of 571.3.

A rigid polyurethane foam was prepared from the refined urea-propylene oxide polyol by mixing 91 grams of this material with 1 gram of silicone emulsifier and 28.5 grams of trichloromonofluoromethane. This blend was then admixed with 100 grams of crude TDI (Nacconate 4040). The blend of reactive materials was mixed at 850 rpm. for seconds. The cream time of the mixture was 13 seconds and its set time was 49 seconds.

This foam had good appearance and fine cells. The skin of the foam was slightly friable and powdery, however, the interior was fairly tough and strong.

EXAMPLE VI Reaction of 1 mole of urea with 3 moles of propylene oxide About 600 grams of urea (10.0 moles) and 1740 grams of propylene oxide (30.0 moles) were reacted by charging urea, 3.52 grams of 85 percent potassium hydroxide and 750 grams of the propylene oxide to a pressure vessel equipped with an agitator and external heating means. The reactor contents were heated to about 270 F., at which point the reaction became exothermic, carrying the temperature of the reaction mixture to about 345 F. The maximum pressure attained during this period was about 300 pounds per square inch gauge. After the peak of the exotherm had passed, the reaction mixture was maintained at about 250 F., while the pressure was maintained in the range of about 75 to about 100 pounds per square inch gauge. The propylene oxide was added incrementally and the pressure was maintained at about 75 pounds per square inch gauge for the remainder of the addition.

After the reaction mixture had cooled and the pressure had diminished, the reactor contents were drained and 2380 grams of reaction product recovered.

About 2324 grams of reaction product were charged to a distillation vessel for purification. The temperature was raised gradually over about a 3-hour period to about 90 C. at atmospheric pressure. During this period, a total of about 19.2 grams of 85 percent phosphoric acid had been added to neutralize the reaction product. The distillation vessel was then placed under a vacuum and the reaction product was vacuum stripped at a temperature of about 120 C. and at a pressure of about 15 millimeters of mercury. Before filtering, about 2304 grams of stripped reaction product were recovered. The stripped reaction product had a hydroxyl value of 657.1, a viscosity of 2230 centipoises at 77 F., and a moisture content of 0.156 percent.

Foams were prepared from the stripped urea-propylene oxide reaction product of Example VI. The formulations and properties of these foams are tabulated in the following table:

EXAMPLE VI, TABLE I Foam VIA was initially friable and powdery on the surface. The interior of the foam was fairly tough. After curing for 24 hours at room temperature, the surface of the foam was still friable.

Foam VIB had only a slight amount of initial friability and was fairly tough internally. This foam had a good appearance and fine cell structure. The foam was still slightly friable after curing at room temperature for 24 hours, however, the surface was tough after curing in excess of 48 hours at room temperature.

The following foam formulation was utilized to prepare a foam for determination of properties at low temperatures.

Two hundred ten (210) grams of an identical foam formulation were charged into a mold having the dimensions of 3 inches by 11 inches by 11%; inches. The top was placed on the mold and the formulation was allowed to cellulate at F. The packing factor of this formulation in this mold is approximately 29.9 percent. The cured foam was removed from the mold. The surface of the foam was fairly friable and some of the skin adhered to the mold. There was no primary shrinkage and the interior of the foam was fairly tough. The density of this foam was 2.10 pounds per cubic foot.

When the molded foam was subjected to l6 F. temperatures for 24 hours, it experienced only very slight shrinkage.

Flame retardant foams were prepared according to the following formulations:

EXAMPLE VI, TABLE 3 Tetramethylbutanediamine Trichloromonofiuoromethane. 29.5 grams. 31.5 grams.

Mixing time at 850 r.p.m.. 13 seconds..." 13 seconds.

Cream time 35 seconds 40 seconds.

Set time 83 seconds. 102 seconds;

Density of cured foam, pounds}:

toot.

Foams VID and VIE were initially friable although they had a fine cell structure and were fairly tough inside. These foams were less friable after curing at room temperature for 24 hours.

0.4 milliliter... 0.4 milliliter.

These foams were tested for fire retardancy according to procedures set forth in ASTMD169259T. Foam VID burned to 1 inch in 24 seconds. After 1.8 inches of the foam had been consumed in 55 seconds, the flame self-extinguished. Foam VIE burned 1 inch in 27 seconds and self-extinguished in 46 seconds after burning 1.3 inches.

To determine the effect upon foam properties, a polyester resin was included in the following foam formulation. This polyester resin was the reaction product of 1 mole of phthalic anhydride and 2 moles of tris(hydroxypropyl) glycerol. The polyester had an acid number of 4.5 and a hydroxyl number of 339.

Foam VIF had a slight amount of initial friability on the surface, although the interior of the foam was tough and the foam had a fine cell structure. After curing for 48 hours at room temperature, the foam became very tough. The density of this foam was 1.81 pounds per cubic foot and the water vapor transmission value was 1.95 perms per inch.

A 2 inches by 2 inches by 1 inch sample of this foam was tested at high temperature and high humidity conditions for distortion resistance. The results are tabulated as follows:

22 EXAMPLE v11 Reaction of 1 mole of urea with 4 moles of propylene oxide in the presence of water and sulfuric acid About 510 grams (8.5 moles) of urea and 1980 grams (34.0 moles) of propylene oxide were reacted in the following manner. The urea, 90 grams of water, and 5.1 grams of concentrated sulfuric acid were charged to a preheated reactor equipped with an external circulating line and temperature measuring device. This mixture was heated to 220 F. and the propylene oxide was added incrementally to maintain the pressure in the reactor at about to about pounds per square inch gauge. The temperature of the reaction was maintained at about 230 F. to 240 F. the addition of the propylene oxide required about 5% hours. After the last increment of propylene oxide had been added, the temperature was continued at about 240 F. for about 5 hours, the pressure steadily dropping, indicating the consumption of the propylene oxide by reaction with urea. After the pressure of the reactor had reduced to 0, the reaction product was drained and 2503 grams were recovered.

The reaction product was vacuum stripped under about 10 millimeters of mercury pressure at a temperature of about 120 C. for about 7 hours.

Of the 2485 grams of reaction product charged, about 2336 grams of the purified reaction product were recovered. About 122 grams of distillate were recovered, having a refractive index of 1.4008, indicating the distillate to contain about 69 percent glycol and about 31 percent water.

The purified reaction product was filtered. The purified reaction product had a Brookfield viscosity of 945 centipoises at 77 F., a hydroxyl content of 689.4, a nitrogen content of 8.97 percent, and a moisture content of 0.076 percent.

The properties of the urea-propylene oxide polyol were evaluated in the preparation of polyurethane foams by reaction with various isocyanates. The results are tabulated in the following table:

EXAMPLE VII, TABLE 1 Foam Ingredients Foam VIIA Foam VIIB VIIC Crude 'IDI (Nccconate 4040) 100 grams.

lgfi dle MDI (Mondur-MR) 100 grams Urea-propylene oxide polyol (OH 689 Silicone emulsifier EXAMPLE VI, TABLE 5 Foam VIIA was friable and powdery on the surface 2-i ch 2-' cl 1-' h 3d. iii and was somewhat friable and weak on the inside.

Test Percent Percent Percent Foams VIIB and VIIC were friable on the surface, but 158F.,100 percentrelativehumidityfor24 60 were tough and strong on the inside. Samples of these hours 2. 2 3. 9 2. 3 F100percentrelativehumidityforl foams (2 nches by 2 inches by 1 1nch dimens ons) were week 2.7 3.1 -2.3 lrnmersed in water for 1 week. The samples did not dis- 100 Percent mauve humldlty 2 tort and no water was found in the interior of the sample.

weeks 1.95 2.2 0 153 F., 100 percent relative humidity m4 The resistance of foams VIIB and VIIC to distortion weeks 2.2 2.7 0 QDOOF'IOT 48 hours" L2 0 at high temperatures and high humidity was evaluated. 200 F. for 1 week 1. 1. 95 0 The results are tabulated as follows:

EXAMPLE VII, TABLE 2 Test Conditions Foam VIIB Foam VIIC 200 F. for 48 hours 0 and 0 percent expansion. No distortion 158 F., percent relative humidity for do 24 hours. 200 F. for 1 week 1 week.

0 ang 0 percent expansion. No distortion.

do D0. 158 F., 100 percent relative humidity for 0 and 0 percent expansion. Very slight distortion 0 and 0.5 percent expansion. Very slight distortion.

The expansion of these foams was checked in two reaction product had a hydroxyl value of 726.7. a moisdirections. ture content of 0.063 percent, a Brookfield viscosity of 788 EXAMPLE V centipoises at 77 F., a nitrogen content of 9.38 percent Reaction of 1 mole of urea with 4 moles of propylene and an ash content of -054 P oxide in water without a catalyst 5 Rigid polyurethane foams were prepared from the About 510 grams (85 moles) of urea and 90 grams of above urea-propylene oxide polyol by reaction with varwater were charged to a preheated reactor equipped wi h ious isocyanates according to the following formulation:

EXAMPLE VIII, TABLE 1 Ingredients Foam VIIIA Foam VIIIB Foam VIIIC Foam VIIID Crude TDI (Nacconate 4040) 100 grams 100 grams Crude MDI (Mondur-M R) 100 grams.

100 grams. 58.0 grams. 1.0 gram.

23.5 grams. seconds. 37 seconds. 71 seconds. 1.61.

Friable surface, strong interior. strong interior.

PAPI Urea-propylene oxide polyol (OH-726.7). Silicone emulsifier Trichlorornonotluoromethane Mixing time at 850 r.p.m Cream time Set time Density of cured foam, pounds per cubic foot Properties of foam after l hour cure at room temperatur 7 seconds 9 seconds.

external recirculating line and external heating means and Foams VIIIC and VIIID were the better foams. These temperature measuring device. This mixture was heated to Qa n Were Cured overnight and were found to have about 22 b f Propylene Oxide addition was begun sllghtly friable surfaces, but strong interiors. These foams About 1980 grams (3 moles) of propylene Oxide were had fine cells, good appearance, and did not undergo any primary shrinkage.

added over approxlmfitely 5 Dmng Pemd the Foams VIIIC and VIIID were tested for fire retardancy temperature was mamtamed at abqut E to about according to procedures set forth in ASTMD169259T. 240 F. and the pressure was maintained at about Foam VIIIC burned 1 inch in 18 seconds and pounds per square inch gaug A r I p py Oxide tin'guished in 27 seconds after burning 1% inches. Foam addition was completed, the reaction mix was ain- VIIID burned 1 inch in 17 seconds and self-extinguished in 29 seconds after burning 1% inches.

d t b t240 F. for a additional 2 hours. The tame a a on n 2 5 The following table illustrates the results obtained when prefsure during this was steadily F f various additives were combined in rigid foam formula catlng the Complete Teactlon of the Propyleng OXlde Wlth tions containing the urea-propylene oxide polyol of this the urea. p

EXAMPLE VIII, TABLE 2 Ingredients Foam VIIIE Foam VIIIF Foam VIII G Foam VIIIH Foam VIII-I PAPI 100.0 grams 100.0 grams 100.0 grams. 100.0 grams, Urea-propylene oxide polyol (OH-726.7) 54.5 grams 51.0 grams. 48.0 grams 47.0 grams. Mixture of monoand dibutyl acid phosphate. 5.0 grams 10.0 grams... LA-700 (condensate of diethylenetriamine with alkyleneolxide) 20.0 grams N, N, N, N-tetrakis (2-hydroxy-propyl) ethylenediamine 10.0 grams. Silicone emulsifier 1.0 g a g 1.0 gram. Trichloromonofluoromcthane 23.5 grams 24.0 grams-.. 24.0 grams. Mixing time at 850 r.p.m. 10 seconds 10 seconds. 10 seconds. Cream time 25 Secon s" 19 seconds 27 seconds. Set time 59 seconds. Density of cured foam, pounds pe 1,46, Over-all foam appearance. v Good Cell structure M m, som Flne Fine- Fine.

open cells.

Foam properties after 24 hours cure at room tem- Friable surface, Extremely weak Slightly friable sur- Tough and strong Friable surface,

perature weak Inte iorand il' ableface, Strong over-all. strong interior.

Flame retardancy according to ASIMD1692 1 inch i 18 S60- 1 inch in 13 seconds, 1 inch in 18 seconds, 1 inch in 13 sec- 59T ends, 5 Inches 1n 2%; inches in 34 2%6 inches in 53 ends, 1%.;

130 seconds. seconds, seliseconds, selfinches in 29 extinguishing. extinguishing. seconds, sellextinguishing.

The reactor was drained and about 2525 grams of re- Foams VIIIE, VIIIG, VIIIH, and VIII-I showed no signs of expansion or distortion when subjected to 200 F. for 48 hours, nor when subjected to 158 F. and high 5 humidity for 24 hours.

The following rigid foam formulations include various action product were recovered.

The reaction product was purified iby charging 2494 grams to a vacuum distillation apparatus. The reaction product was stripped at about 10 millimeters of mercury polyol additives with the urea propylene oxide p y of Pressure at a ternPerature of about 120 for about 1/2 this example in order to determine the effect of such hours. About 2367 grams of purified reaction product additives upon the properties of the resulting foams. The

were recovered. About 80 grams of distillate were re- Polyester additive having a y y number of 378 and i h t c 13682, an acid number of 7.86 is the reaction product of 1 mole covered The refracnve Index of t e la 6 W18 of phthalic anhydride with 2 moles of tris(hydroxypropyl) indicating that it contained about 36 percent glycol and glyceroL The phosphorus poly 01 having a hydroxyl num about 64 Pacer!t Waterber of about 261 is the reaction product of propylene oxide The purified reaction product was filtered. The filtered with a mixture of monoand dibutyl acid phosphate.

EXAMPLE VIII, TABLE 3 Ingredients Foam VIIIJ' Foam VIIIK Foam VIIIL Foam VIIIM PAPI 1050 grams 105.0 grams 105.0 grams 105.0 grams. Polyester polyol (OH-378) 30.0 grams 30.0 grams. Urea-propylene oxide polyol (OH-726.7). 42.0 grams- 38.0 grams 51.0 grams. 47.0 grams. Phosphorus polyol (OH-261) 10.0 grams Trimethylopropene-propylene oxide reaction product having a hydroxyl number of 230 20. grams Trimethylopropene-propylene oxide reaction product having a hydroxyl number of 400 20.0 grams. Silicone emulsifier 1.0 gram. 1.0 gram. 1.0 gram. Trichloromonofluoromethane. 29.0 grams 30.0 grams 28.0 grams. Tetramethylbutanediamine. 0.3 milliliter. Mixing time at 850 r.p.m---. 8 seconds 10 seconds 10 seconds. Cream time 9 seconds 33 seconds. Set time seconds.-. 86 seconds. Density of cured foam, pounds per cubic foot .55 1.48. Foam appearance Good Good Cell structure Fine Fine Fine Fine. Foam properties after curing at room temperature for 16 hours Strong, tough sur- Strong, tough sur- Slightly friable sur- Slightly friable surface and interior. face and interior. face, tough face, tough interior. interior. Flame retardancy according to ASTM-D-1692-59-T 1 inch in 17 seconds, 1 inch in 20 seconds, 1 inch in 14 seconds, 1 inch in 14 23%; inches in 1% inches in 35 27%; inches in 37 seconds, 3% seconds, selfseconds, selfseconds, selfinches in 51 extinguishing. extinguishing. extinguishing. seconds, selfextinguishing.

cent, an ash content of 113 parts per million, and a hydroxyl value of 738.5.

Rigid polyurethane foams were prepared from the above ureaipropylene oxide-ethylene oxide polyol according to the following formulations:

EXAMPLE IX, TABLE 1 Silicone emulsifier 1.0 gram 1.0 gram 1.0 gram.

Trichlorornonofluoromethane.

. 23.5 grams 23.5 grams.

Mixing time at 850 r.p.m 10 seconds 10 seconds. Cream time 16 seconds 32 seconds. Set time 34 seconds 43 seconds".-- 68 seconds. Compatibility of isocyanate and polyolpremix Good Good Good.

urea, 4 moles of propylene oxide and 1 mole of ethylene oxide in the following manner:

About 400 grams (6.66 moles) of urea, 70 grams of water and 2.0 grams of concentrated sulfuric acid were admixed until a solution had formed. This solution was charged to a preheated reactor having an external circulating line, external heating means and temperature measuring device. While maintaining the temperature at about 240 F., a total of 1550 grams (26.8 moles) of propylene oxide were added to the reaction mixture at a rate sufficient to maintain the reaction pressure at about 60 pounds per square inch gauge. The propylene oxide addition required about 4 /2 hours. Then, while maintaining the temperature at about 240 F., about 295 grams of ethylene oxide were added over about a 1-hour period at a rate sufficient to maintain the reaction pressure at about 60 pounds per square inch gauge. While maintaining the reaction temperature at about 240 F. for an additional 4 hours, the reaction was allowed to continue until the reaction pressure was about 0 pound per square inch gauge.

The reaction vessel was drained and about 2255 grams of reaction product were recovered. About 1942.2 grams of this reaction product was purified by distilling at a temperature of about 112 C. to about 120 C. at a vacuum of 10 millimeters of mercury pressure for about 1 hour. About 4 grams of distillate were recovered which contained about 12.5 percent glycol and about 87.5 percent water. About 1935.6 grams of reaction product were recovered. The reaction product had a nitrogen content of 7.94 percent, a moisture content of 0.047 per- Foam DCA became very hot during the foaming action. The resulting foam had a number of fissures and was extremely friable and weak.

Foam IXB had a friable surface and tough interior after curing at room temperature for 1 hour. After curing at room temperature for 16 hours, the surface of the foam Was still friable and the interior was strong and not friable. This foam had fine cells and good appearance.

Foam IXC had a friable surface and strong interior after curing at room temperature for 1 hour. After curing at room temperature for 16 hours, the foam had a friable surface and a strong, tough interior. The appearance of this foam was good and it possessed fine cells.

Rigid polyurethane foam blown with carbon dioxide was prepared from the above urea-propylene oxide-ethylene oxide polyol according to the following formulation:

The resulting foam had a good rise and contained good cell structure. The foam was not friable after curing at room temperature for 1 hour.

27 EXAMPLE X Reaction of 1 mole of urea with 2.7 moles of propylene oxide in water with triethylamine catalyst A solution was prepared of 510 grams (8.5 moles) of urea, 90 grams of water, and 10.2 grams of triethylamine by adding the urea and triethylamine to the Water while maintaining the temperature of the water above about 50 C. This solution was charged to a preheated reactor having an external recirculating line, external heating means, and temperature recording device. While maintaining the temperature of the reaction mixture at about 230 F. to 270 F., about 1340 grams of propylene oxide were added incrementally at a rate sufiicient to maintain the reaction pressure at about 50 to 60 pounds per square inch gauge. The propylene oxide addition required about 7 hours. After the reaction vessel had cooled about 1728 grams of reaction product were recovered.

About 1666 grams of the reaction product were vacuum stripped under a vacuum of about millimeters of mercury pressure at a temperature of about 80 C. to about 120 C. for about 3 hours. At this point, about 9 grams of 85 percent phosphoric acid were added and the vacuum stripping was continued under about 10 millimeters of mercury pressure and at a temperature of about 100 C. to 125 C. After the acid addition, the distillation was carried on for a period of about 5 hours.

The purified reaction product was filtered and about 1499 grams were recovered which had a hydroxyl number of 710.0, a viscosity of 8010 centipoises, a moisture content of 0.112 percent, and a nitrogen content of 12.33 percent.

Rigid polyurethane foams Were prepared from a blend of the above urea-propylene oxide polyols and a polyol having a hydroxyl number of 502 prepared from 1 mole of dipropylene glycol and 2 moles of ethylene oxide.

moles of trimethylol-propane having a hydroxyl number of 404 and a viscosity of 55,000 centipoises.

EXAMPLE XI, TABLE 1 Foam XIA Ingredients: Grams PAPI 100.0

Blend of /50 urea-ethylene oxide polyol Set time 45-50 The resulting foam rose satisfactorily and had a good cell structure. There was no initial shrinkage or distortion.

EXAMPLE XII Rigid polyurethane foams were prepared from the following polyols: Control polyol (OH-780), N,N,N',N'- tetrakis(2-hydroxypropyl)ethylene diamine; Polyol A (OH-611), product of the reaction of 1 mole. of urea with 4 moles of propylene oxide in the presence of 0.5 percent sulfuric acid at a temperature of about 230 F. to 240 F. and a pressure of about pounds per square inch gauge in one stage; Polyol B (OH598), similar to Polyol A; Polyol C (OH-594), the product of the reaction of 1 mole of urea with 4 moles of propylene oxide at a temperature of about 230 F. to 240 F. and a pressure of about 55 pounds per square inch gauge, and in the absence of any catalyst of reaction; Polyol D (OH-586), similar to Polyol C; Polyol E (OH-601), the product of the reaction of 1 mole of urea with 4 moles of propylene oxide at a temperature of about 260 F. to 270 F. and

EXAMPLE X, TABLE 1 Ingredients Foam XA Foam XB Foam XC Foam DX Crude MDI (Mondur-MR) 100.0 grams. 100.0 grams. 100.0 grams. 100.0 grams. Urea-propylene oxide polyol (O H710).. 36.8 grams 36.8 grams- 36.8 grams. 28.4 grams. Digglolpyllezgie glycolethylene oxide polyol ..-.-do ..do do.-. 42.6 grams.

5 Silicone emulsifier 0.6 gram....--... 0.6 gram 0.6 gram... 0.6 gram. 1.8 DMEA/OJ DAB CO 0.8 gram 0.4 gram 0.1 gram. Trichloromonofluoromethane 29.0 grams. 29.0 grams 29.0 grams 28.0 grams. Mixing time at 850 r.p.m 10 seconds 10 seconds..- 10 seconds. 10 seconds. Cream time 24 seconds. 27 seconds 48 seconds. 45 seconds. Set time 55 seconds 69 seconds-. 90 seconds. 85 seconds. D%nsity of cured ioam, pounds per cubic 1.6 1.55 57 1.57.

not. Foam surface Slight initial Slight initial Slight initial Slight initial friability. friability. iriability. iriability. Foam appearance Good Goo Foam interior Tough Primary shrinkage I. Percent expansion after 24 hours at 1 F.

and high humidity.

Slight 2.7

Percent expansion after 2 weeks at 158 F. 19.5 12.5 9.0 8.6.

and high humidity. Percent expansion after 48 hours at 200 F. 15.5 10.9 4.3 6.7.

EXAMPLE XI Urea-ethylene oxide foams A polyol Was prepared from 1 mole of urea and 5 moles of ethylene oxide according to the procedure outlined in Example V. The purified polyol had a hydroxyl number of 949.8, a moisture content of 0.094 percent by weight, and a nitrogen content of 8.65 percent by weight.

A rigid urethane foam blown with methylene chloride and carbon dioxide was prepared from a blend of 31 grams of the above polyol and 31 grams of the reaction at a pressure of about 55 to 60 pounds per square inch gauge, and in the absence of any catalyst of reaction; Polyol F (OH-613), the product of the reaction of lmole of urea with 4 moles of propylene oxide at a temperature of about 230 F. to 245 F. under a pressure of about to pounds per square inch gauge, and in the absence of any catalyst of reaction; Polyol G (OH-604), similar to Polyol F; Polyol H (OH604), prepared similar to Polyol F, although having a urea to propylene oxide ratio of 1 to 3. 3

Rigid polyurethane foams were prepared from the product of 2 moles of a long chain dimer acid and 6 75 above polyols according to the following formulation.

EXAMPLE XII, TABLE 1 Foam Foam Foam Foam Foam Foam Foam Foam Ingredients Control XIIA XIIB XIIC XIID XIIE XIIF XIIG XIIH PAPI, grams 100. 100. 0 100. 0 100. 0 100. 0 100. 0 100. 0 100. 0 Polyol, grams. 69. 0 70. 0 71. 0 72. 0 70. 0 68. 69. 5 68. 0 Silicone emulsifier, gram 1. 0 1. 0 1. 0 1. 0 1. 0 1. 0 1. 0 1. 0 1. 0 Tetramethylbutane-diamglne, grams 0. 16 0. 16 0. 16 0. 16 0. 16 0. 16 0. 16 0. 16

' loromonofluoro-met ane,

231115 25.5 25.4 25. 5 25. 7 25. 8 25. 5 25. 3 25. 5 25. 3 Mixing time at 850 r.p.m., seconds 12 15 15 15 15 15 15 15 Cream time, seconds 43 45 40 43 43 43 45 45 Set time, seconds 25 95 99 83 93 97 103 99 86 Density, pounds per cubic foot 1. 69 1. 67 1. 67 1. 67 1. 67 1. 67 1. 67 1. 67 1. 67 Time to burn 1 inch, seconds 14 22 17 22 14 15 13 Total burning time, seconds- 54 64 60 73 60 65 67 44 Total number of 3. 2 3. 7 2- 4 3. 4 3. 5 3. 5 3. 8 1. 9

1 Completely consumed (more than 5 inches).

Nora-The above flame retardancy tests were conducted in accordance with ASfIM D- 169259T procedure. According to that test, Foams XIIA through XIIH were characterized as self-extinguishing.

Although the nitrogen content of Foam XII Control (8.69 percent) and the nitrogen content of Foams XIIA through XIIH (8.64 percent) were almost identical, the flame retardancy was remarkably different. Foam XII Control was completely consumed when ignited in accordance with the procedures set forth in ASTM-D- 1692-59T, While Foams XIIA through XIIH were all self-extinguishing according to the ASTM procedure.

ASTM-D-l692-59T procedure involves igniting one end of a 2 inches by 6 inches by /2 inch foam specimen with a Bunsen burner having a wing-top producing a 1% inches high flame. The specimen has marks at 1 inch and 5 inches from the ignited end. The flame of the burner is held to the end of the foam for 1 minute and then removed. If the 1 inch mark is not reached at the end of 1 minute, the specimen is considered non-burning. If the foam ceases to burn before reaching the 5-inch mark, the specimen is considered self-extinguishing.

EXAMPLE XIII To illustrate another method of preparing novel N-containing polyols which produce self-extinguishing foams when reacted with an organic polyisocyanate, one molar equivalent of urea was reacted with one molar equivalent of triisopropanolamine, and this reaction product was further reacted with one molar equivalent of propylene oxide to produce Polyol A and with two molar equivalents of propylene oxide to produce Polyol B. The following procedures were utilized.

Polyol XIIIA About 1335 grams (7.0 moles) of triisopropanolamine were charged to a reaction vessel equipped with a reflux condenser and nitrogen inlet. As the triisopropanolamine was heated, the urea was added incrementally until 420' grams (7.0 moles) of urea had been added. The temperature of the reaction was maintained at about 125 C. to 130 C. The reaction was continued for a period of about 7 hours. The reaction product had a hydroxyl value of about 710, an amine equivalent of 205, a nitrogen content of 13.24 percent, and a free urea content of 6.67 percent.

About 1140 grams (4.87 moles) of the above reaction product were reacted with 283 grams (4.87 moles) of propylene oxide. The reaction product Was charged to a preheated reactor having an external recirculating line connected to a heat exchanger, and heated to 220 F. The propylene oxide was added incrementally over a 15-minute period. The reaction was continued for about 6 hours at a temperature of about 220 C. to about 230 C..The maximum pressure attained in the reactor was about 50 pounds per square inch gauge, and the completion of reaction was indicated by the diminishing pressure.

The crude product from the alkylene oxide reaction was vacuum distilled for about 2 hours at a maximum temperature of about 100 C. and a pressure of about 10 millimeters of mercury. The final reaction product (Polyol A) bad a Brookfield viscosity at 77 F. of 26,900 centipoises and an alkalinity value of 0.43, a free urea content of 3.40 percent, a hydroxyl value of 680.9, a

moisture content of 0.053 percent, an amine equivalent of 229, and a nitrogen content of 10.87 percent.

Polyol XIIIB About 1673 grams (8.8 moles) of triisopropanolamine were reacted with 527 grams (8.8 moles) of urea in a manner similar to that set forth for Polyol A. The reaction product had a hydroxyl value of 712, an amine equivalent of 205, a nitrogen content of 13.4 percent, and a free urea content of 6.18 percent.

An alkylene oxide derivative of the above reaction product was prepared by reacting about 1270 grams (5.43 moles) of the above reaction product with about 630 grams (10.86 moles) of propylene oxide. The reaction was conducted by charging the reaction product to a preheated reactor and heating to about 220 F. Propylene oxide was added incrementally over a period of about 4 hours. The reaction temperature was maintained at about 220 F. to 240 F., and the maximum pressure reached during the reaction was about 60 pounds per square inch gauge. The reaction was continued for a period of about 7 hours. The alkylene oxide reaction product was vacuum distilled at a maximum temperature of about C. for a period of about 1 hour and 15 minutes under pres sure of about 11 millimeters of mercury.

The final reaction product (Polyol B) had a Brookfield viscosity at 77 F. of 14,750 centipoises, a hydroxyl value of 724.8, a nitrogen content of 9.80 percent, an amine equivalent of 234.6, and a free urea content of 3.22 percent.

The above polyhydroxy resinous materials, Polyol XIIIA and Polyol XIIIB, Were reacted With an organic polyisocyanate according to the following formulations to form polyurethane foams.

EXAMPLE XIII, TABLE 1 Ingredients Foam XIIIA Foam XIIIB Poly-methylene polyphenyl isoc anate 100.0 rams"--. n ii i' m 4 d y g in any me ene-4, iisocyanate 100.0 ra

(Moudur-MR). g ms Polyol A 62.0 germs Polyol B 58.0 grams. Silicone emulsifier 1.0 gram 1.0 gram. Tetramethylbutanediamine 0.5 milliliter 0 5 milliliter Trichloromonofluoromethane 24.0 grams.

Mixing time at 850 r.p.m. (mecha 20 seconds.

stirrer).

Cream time 25-30 seconds 25-30 seconds.

Set time 3540 seconds. 50-55 seconds.

Density, pounds per cubic foot 2.01 2.0.

31 Both of the foams are considered self-extinguishing according to the standards set forth in ASTM-D-l692- 59T.

Similar results are obtained when triethanolamine is substituted for triisopropanolamine in the above example.

Comparison tests To illustrate the unique properties of the above foams, it was attempted to prepare a foam by reacting an organic polyisocyanate with the reaction product of an aliphatic polyol, such as trimethylolpropane, and urea. One mole of trimethylolpropane (TMP) was reacted with one mole of urea in a manner similar to that set forth in Example XIII for the reaction of triisopropanolamine and urea. The trimethylolpropane-urea reaction product had a hydroxyl number of 735, a nitrogen content of 8.57 percent, an amine equivalent of 1760, and a urea content of 5.24 percent.

The urea-trirnethylolpropane reaction product was reacted with polymethylene polyphenyl isocyanate in the presence of 23.8 grams of trichloromonofiuoromethane and 0.2 milliliter of tetramethylbutane diamine. No foam resulted.

Similarly, it was attempted to prepare a foam from the reaction product of triisopropanolamine (1 mole) and urea (1 mole). The reaction as conducted above in Example XIII resulted in a polyhydroxy material having a hydroxyl number of 710, a nitrogen content of 13.24 percent, an amine equivalent of 205, and a free urea content of 6.67 percent. The reaction of this product with polymethylene polyphenyl isocyanate in the presence of 24 grams of trichloromonofluoromethane and 1.0 milliliter of tetramethylbutanediamine did not result in a foam.

EXAMPLE XIV A polyurethane foam was prepared from the reaction product of 1 mole of urea and 2 moles of propylene oxide which had a hydroxyl value of 838 and a Brookfield viscosity at 77 F. of 9030 centipoises. About 8.1 grams of this material and 2.0 grams of the reaction product of a long chain dimer acid (2 moles) and trimethylolpropane (6 moles) having a hydroxyl value of 403.6 were reacted with grams of polymethylene polyphenyl isocyanate in the presence of 0.2 gram of a silicone emulsifier, 0.15 gram of an 8.0 percent copper naphthenate solution, 0.1 milliliter of tetramethylbutanediamine and 4.7 grams of trichloromonofiuoromethane. The ingredients were handmixed for seconds at a set time of about 90 seconds.

The resulting foam did not exhibit any shrinkage after 24 hours.

EXAMPLE XV Polyurethane foams were prepared from a reaction product of 1 mole of urea and 4 moles of 1,2-butylene oxide having a hydroxyl value of 614. The following table sets forth the proportions of the ingredients utilized in the preparation of these polyurethane foams.

Set time .I.. secon ls. 43 seconds.

Foam XVA had good appearance, fine cell structure and a density of 1.95 pounds per cubic foot. The foam was tough and had only slight surface friability.

Foam XVB had good appearance, fine cell structure and a density of 2.11 pounds per cubic foot. The foam was fairly tough and had moderate surface friability.

In the above examples, similar results are achieved when dichlorodifluoromethane is substituted for trichloromonofiuoromethane. v

Although the above examples depict the invention in detail, the invention is not to be construed as limited solely thereto, but to include all the embodiments set forth in the following claims. I.

What is claimed is:

1. A hydroxyl-group containing composition prepared by reacting a urea of the formula: v

wherein X is a chalcogen atom in one of the short periods of the Periodic Table, and R is hydrogen, lower alkyl, hydroxyalkyl, phenyl or benzyl with about 2 to 20 moles per mole of said urea of alkylene oxide having 2 to 10 carbon atoms at super-atmospheric pressure and elevated temperature.

2. A composition as in claim 1 wherein the alkylene oxide contains 2 to 4 carbon atoms.

3. A composition as in claim 2 wherein the alkylene oxide contains 3 or 4 carbon atoms.

4. A composition as in claim 1 wherein X is oxygen.

5. A composition as in claim 4 wherein the alkylene oxide contains 2 to 4 carbon atoms. 1

6. A composition as in claim 5 wherein the alkylene oxide contains 3m 4 carbon atoms.

7. A composition as in claim 4 wherein R is hydrogen or hydroxyalkyl containing 2 to 4 carbon atoms and where the reaction is conducted at a temperature between about F. and about 500 F. at a pressure between about 10 and about 300 p.s.i.g.

8. A composition as in claim 7 wherein the alkylene oxide contains 2 to 4 carbon atoms.

9. A composition as in claim 8 wherein the alkylene oxide contains 3 or 4 carbon atoms.

10. A composition as in claim 9 wherein the reaction is conducted at a temperature between about 200 F. and about 300 F. at a pressure between about 50 and about p.s.i.g.

11. A method of preparing a hydroxyl-group containing composition which comprises reacting a urea of the formula:

wherein X is a chalcogen atom in one of the short periods of the Periodic Table, and R is hydrogen, lower alkyi, hydroxyalkyl, phenyl or benzyl with about 2 to 20 moles per mole of said urea of alkylene oxide having 2 to 10 carbon atoms at super-atmospheric pressure and elevated temperature.

12. A method as in claim 11 wherein X is oxygen, R is hydrogen or hydroxyalkyl containing 2 to 4 carbon atoms and the reaction is conducted at a temperature between about 200 F. and about 300 F. at a pressure between about 50 and about 150 p.s.i.g.

(References on following page) 34 References Cited Silverstein et al., spectrometric Identification of Organic Compounds, John Wiley, New York (1963). UNITED STATES PATENTS Library of Congress Catalog Card No. 63-11450.

2,822,349 2/1958 et 260-75 Condensed Chemical Dictionary, 5th Edition, Rein- 2,842,523 8/1958 Touslgnantet 260-69 hold, New York (1956), p. 941. Call No. QD5C5. 2,876,260 3/1959 Huyser et a1 260-553; 5 3,038,008 6/1962 Richter 260-553,, DONALD E. CZAJA, Primary Examiner 3,255,253 6/1966 Kuryla 260-584 I 3,277,027 10/1966 Hennig et a]. 260 2.s COCKERAM Assstam Exammer 3,368,985 2/ 1968 W1smer et a1 260--2.5 US. Cl.

OTHER REFERENCES Tousignant et al., Journal of Organic Chemistry, vol. 22, pp. 166-167 (1957).

5,3 3 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,519,680 Dated July 7, 1970 Inventor(s) Marco Wismer, James F. Foote and Paul R. Mosso It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 3, "Joseph F. Foote" should read ----James F. Foote--- SIGNED N s (SEAL) Amst:

Edward M. Fletcher, It. mm B. SGHUYLER, JR.

3, Anesting omissionor of Patents 

